Cebora BRAVO SYNERGIC MIG 613 Service Manual
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Cebora BRAVO SYNERGIC MIG 613 Service Manual

Power sources + wire feeders
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CEBORA S.p.A.
1
BRAVO SYNERGIC MIG
POWER SOURCES arts. 613 - 615 - 617 - 619 +
WIRE FEEDERS arts. 1652 - 1654
SERVICE MANUAL
3.302.197
11/04/05

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Summary of Contents for Cebora BRAVO SYNERGIC MIG 613

  • Page 1 CEBORA S.p.A. BRAVO SYNERGIC MIG POWER SOURCES arts. 613 - 615 - 617 - 619 + WIRE FEEDERS arts. 1652 - 1654 SERVICE MANUAL 3.302.197 11/04/05...

  • Page 2: Table Of Contents

    CEBORA S.p.A. CONTENTS - GENERAL INFORMATION......................3 - Introduction............................3 - General service policy........................3 - Safety information..........................3 - Electromagnetic compatibility.......................3 - SYSTEM DESCRIPTION........................4 - Introduction............................4 - Technical specifications.........................4 - Welding system description......................4 - Description of power sources......................4 - Description of wire feeders.

  • Page 3: General Information

    It is forbidden to attempt to repair damaged electronic boards or modules; replace them with original Cebora spare parts. 1.3 - Safety information. The safety notes provided in this manual are an integral part of those given in the Instruction Manual.

  • Page 4: System Description

    CEBORA S.p.A. 2 - SYSTEM DESCRIPTION 2.1 - Introduction. BRAVO SYNERGIC MIG is a system for welding mild and stainless steel and aluminium, using a synergic MIG process, consisting of electrical power sources with separate detachable wire feeders and a range of accessories to adapt to various types of use (see list in the Sales Catalogue).

  • Page 5: Description Of Wire Feeders

    CEBORA S.p.A. The 16 Vac secondary voltage powers the timing board (50), which manages the pump and fan on the cooling unit through the socket (12), the fan (43) of the power source, and the circuit corresponding to the safety devices of the welding system (thermostat on the power transformer (48), flow meter on the cooling unit and microswitch on the guard of the wire feed unit).

  • Page 6: Maintenance

    CEBORA S.p.A. 3 - MAINTENANCE WARNINGS ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. DISCONNECT THE POWER SOURCE FROM THE MAINS BEFORE PERFORMING MAINTENANCE. 3.1 - Periodic inspection, cleaning. Periodically remove dirt and dust from the internal parts of the power source, using a jet of low-pressure dry compressed air or a brush.

  • Page 7: Wire Feeder Commands And Connections

    CEBORA S.p.A. 3.2.2 - Wire feeder commands and connections. 3.2.3 - Welding system operation. System shut off and disconnected from the mains. Connect the gas supply to the fitting (Q) on the wire feeder. Connect the signal cable, built into the connection extension, to connectors (R) on the wire feeder and (F) on the power source.
  • Page 8 CEBORA S.p.A. ♦ After two seconds, display (H) shows the wire speed programmed for the manual program, or, for synergic programs, the programmed current based on the position of switches (33) and (34) and knob (P). Correct? NO (see 3.3.1, 3.3.3).
  • Page 9 CEBORA S.p.A. Use the keys (E), (O) or (N) to select a saved synergic program (see Instruction Manual and table provided in the compartment of the wire feed unit). ♦ Display (H) indicates the selected program number (ex.: P01). ♦ After 1 second display (H) shows the programmed value of the measurement indicated by lighting one of the leds (M), (L) or (I).

  • Page 10: Troubleshooting

    CEBORA S.p.A. 3.3 - Troubleshooting. WARNINGS ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. DISCONNECT THE POWER SOURCE FROM THE MAINS BEFORE PERFORMING MAINTENANCE. NOTES Items in boldface describe problems that may occur on the machine (symptoms).
  • Page 11 CEBORA S.p.A. ♦ Check the wiring between service transformer (35), connector (15) on the power source, connector (14) on the wire feeder, and motor control board (36). ♦ Make sure the setting of the voltage change terminal board (45) matches the mains voltage.

  • Page 12: Power Source Powered, Control Panel On, Fan (43) Does Not Work

    CEBORA S.p.A. 3.3.2 - Power source powered, control panel on, fan (43) does not work. NOTE The fan (43) may be activated using the start command of the torch button, and continues running after it is released for the time set on the timing board (50)(approximately 10 minutes).

  • Page 13: Control Panel On, Display And Signals Do Not Show Correct Values

    CEBORA S.p.A. board (50) and service transformer (35), and replace motor control board (36) if necessary. ♦ Make sure the power supply to the service transformer (35) is correct performing if necessary the MOTOR CONTROL BOARD (36) POWER SUPPLY TEST in par.

  • Page 14: The Start Button Produces No Effect

    CEBORA S.p.A. 3.3.4 - The start button produces no effect. POWER SOURCE SAFETY TEST. Motor control board (36), connector J2, terminals 7 and 8 = 16 Vac (no alarms present). Correct? ♦ See “Alarm signals”, par. 3.4. START COMMAND TEST.

  • Page 15: System Powered, No Gas Flows From The Torch

    CEBORA S.p.A. 3.3.5 - System powered, no gas flows from the torch. SOLENOID VALVE (6) TEST. Solenoid valve (6) terminals = 27 Vac with torch button pressed and for as long as the button is held down, plus the post-gas time.

  • Page 16: Power Source Powered, The Wire Feeder Motor Does Not Work

    CEBORA S.p.A. 3.3.6 - Power source powered, the wire feeder motor does not work. WIRE FEEDER MOTOR TEST. Use the buttons (E), (N) or (O) to select the manual working program (P00 on display (H)). Motor (36) control board, connector J8, terminals 1 (+) and 2 (-) = approximately +2.5 / +12 Vdc, adjustable using the knob (P), with start button pressed.

  • Page 17: In Open Circuit Operation, The Output Voltage Is Not Regular

    CEBORA S.p.A. 3.3.7 - In open circuit operation, the output voltage is not regular. NOTE When the switches (33) and (34) are set to certain positions, the secondary voltage values between phases are different due to the particular connections between switches (33) and (34) and the primary circuit of the transformer (48).
  • Page 18 CEBORA S.p.A. Correct? ♦ Check the wiring between the contactor (38) coil, service transformer (35), power source connector (15), wire feeder connector (14) and terminal 5 of J7 on motor control board (36). ♦ Check the supply voltage for the motor control board (36), performing if necessary the MOTOR CONTROL BOARD (36) POWER SUPPLY TEST in par.
  • Page 19 CEBORA S.p.A. Correct? ♦ Check the wiring between the secondary transformer (48) circuit and rectifier (42). ♦ Check the efficiency of the rectifier bridge (42). ♦ Check the wiring between the negative terminal of rectifier bridge (42), choke (40) (where present), output terminal (-)(D) of the power source, and between the...

  • Page 20: In Resistive Load Operation, The Output Voltage Is Not Regular

    CEBORA S.p.A. 3.3.8 - In resistive load operation, the output voltage is not regular. NOTE Only the test loaded at the maximum output voltage is described below, and thus at the maximum current of the power source, since it is assumed that the OPEN CIRCUIT OPERATION TEST in par.

  • Page 21: In Synergic Mode, The Welding Quality Is Not Satisfactory, The Wire Speed Is Not Suited To The Output Current

    CEBORA S.p.A. 3.3.9 - In synergic mode, the welding quality is not satisfactory, the wire speed is not suited to the output current. NOTE The parameters entered into the synergic programs are drawn from experience, and thus some operators may find themselves working in ideal conditions, while others may need to make slight changes.

  • Page 22: When Start Button Is Released, The Wire Sticks To The Workpiece (Ineffective Motor Braking)

    CEBORA S.p.A. 3.3.11 - When start button is released, the wire sticks to the workpiece (ineffective motor braking). NOTE The “Burn-Back” function is included in the work programs and is adjustable via the control panel (see Instruction Manual). With this function the power source delays stopping current generation during the slowdown of the wire output from the torch, since even though it brakes after welding, the wire feeder motor still requires a certain amount of time to come to a complete stop.

  • Page 23: Alarm Signals

    CEBORA S.p.A. 3.4 - Alarm signals. 3.4.1 - Led (F) lit = transformer (48) temperature too high, or wire coil cover open, or cooling liquid flow low, or fuse on 16 Vac power supply tripped. This signal is activated by four different situations: −...

  • Page 24: Components List

    CEBORA S.p.A. 4 - COMPONENTS LIST 4.1 - Power sources arts. 613-615-617-619: see file ESP61*.pdf enclosed at the end of the manual. 4.2 - Wire feeders arts. 1652-1654: see file ESP165*.pdf enclosed at the end of the manual. 4.3 - Power sources components table: see file ESP61*.pdf enclosed at the end of the manual.

  • Page 25: Electrical Diagrams

    CEBORA S.p.A. 5 - ELECTRICAL DIAGRAMS 5.1 - Power sources arts. 613-615-617-619: see file SCHE61*.pdf enclosed at the end of manual. 5.2 - Wire feeders arts.1652-1654: see file SCHE165*.pdf enclosed at the end of the manual. 5.3 - Waveforms. 5.3.1 - Wire feeder motor (402/403) voltage during correct braking (par. 3.3.11).

  • Page 26: Timing Board (50) Code 5.602.211

    CEBORA S.p.A. 5.4 - Timing board (50) code 5.602.211. 5.4.1 - Topographical drawing. 5.4.2 - Connector table. Conn. Terminals Function. 1 - 2 16 Vac input timing board (50), safety circuits and start button on the torch power supply. 3 - 4 signal input from flow meter on cooling unit.

  • Page 27: Motor Control Board (36) Code 5.602.205

    CEBORA S.p.A. 5.5 - Motor control board (36) code 5.602.205. 5.5.1 - Topographical drawing. 5.5.2 - Connector table. Conn. Terminals Function. 1 - 2 start signal input from torch button. 1 - 2 3 / 4-5-6 pre-selection inputs from switch (34) on art. 613 or switch (33) on arts. 615, 617, 619.
  • Page 28 Art. 613...
  • Page 29 Art. 615 - 617 - 619...
  • Page 30 Artt. 613 - 615 - 617 - 619 pos DESCRIZIONE DESCRIPTION pos DESCRIZIONE DESCRIPT 01 LATERALE SINISTRO LEFT SIDE PANEL 28 CAVO MASSA EARTH CABLE 02 MANICO HANDLE 29 PANNELLO ANTERIORE FRONT PANEL 03 SUPPORTO MANICO HANDLE SUPPORT 30 CORNICE FRAME 04 LATERALE FISSO FIXED SIDE PANEL...
  • Page 33 Artt. 1652 - 1654 pos DESCRIZIONE DESCRIPTION pos DESCRIZIONE DESCRIPTION 01 CHIUSURA CLOSING 32 CORPO ADATTATORE ADAPTOR BODY 02 LATERALE SINISTRO LEFT SIDE PANEL 33 MANOPOLA KNOB 03 PIANO INTERMEDIO INSIDE BAFFLE 34 CORNICE FRAME 04 PULSANTE SWITCH 35 PROTEZIONE PROTECTION 05 PANNELLO POSTERIORE BACK PANEL...

This manual is also suitable for:

Bravo synergic mig 615Bravo synergic mig 617Bravo synergic mig 619Bravo synergic mig 1652Bravo synergic mig 1654

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